90+ MULTIPOSITIONAL GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents

90+ MULTIPOSITIONAL GAS FURNACE INSTALLATION INSTRUCTIONS Table of Contents
90+ MULTIPOSITIONAL GAS FURNACE
INSTALLATION INSTRUCTIONS
Table of Contents
GAS FURNACE SAFETY................................................................1
INSTALLATION REQUIREMENTS ................................................3
Tools and Parts ............................................................................3
Location Requirements ................................................................3
Installation Configurations ...........................................................4
Ductwork Requirements ..............................................................4
Electrical Requirements ...............................................................4
Gas Supply Requirements ...........................................................4
Venting Requirements..................................................................4
INSTALLATION INSTRUCTIONS ..................................................5
Inspect Shipment .........................................................................5
Plan Vent System .........................................................................6
Determine Vent Pipe Direction.....................................................8
Connect Venting.........................................................................15
Install Condensate Disposal.......................................................15
Connection to Pressure Switch .................................................18
Install Ductwork..........................................................................19
Filter Specifications ....................................................................19
Make Electrical Connections .....................................................20
Make Gas Connections..............................................................20
Check the Furnace Input Rate ...................................................21
Adjust the Furnace Input Rate ...................................................21
Complete Installation..................................................................22
Sequence of Operation ..............................................................23
Controls ......................................................................................23
TROUBLESHOOTING ..................................................................24
ASSISTANCE OR SERVICE .........................................................27
Accessories ................................................................................27
GAS FURNACE SAFETY
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety
messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.”
These words mean:
DANGER
WARNING
You can be killed or seriously injured if you don't immediately
follow instructions.
You can be killed or seriously injured if you don't follow
instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can
happen if the instructions are not followed.
Whirlpool® and Whirlpool Gold™
Models WFCT, WGFDT
47861K005
Whirlpool® Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258
IMPORTANT SAFETY INSTRUCTIONS
■
■
■
■
■
■
■
Use only with type of gas approved for this furnace.
Refer to the furnace rating plate.
Install this furnace only in a location and position
as specified in the “Location Requirements” section
of these instructions.
■
Provide adequate combustion and ventilation air to
the furnace space as specified in the “Venting
Requirements” section of these instructions.
When a furnace is installed so that supply ducts
carry air circulated by the furnace to areas outside
the space containing the furnace, the return air
shall also be handled by duct(s) sealed to the
furnace casing and terminating outside the space
containing the furnace.
■
Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system
only, as specified in the “Venting Requirements”
section of these instructions.
■
A gas-fired furnace for installation in a residential
garage must be installed as specified in the
“Location Requirements” section of these
instructions.
The furnace is not to be used for temporary heating
of buildings or structures under construction.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made
specifically for the detection of leaks to check all
connections, as specified in the “Make Gas
Connections” section of these instructions.
Adequate clearance must be provided around the
vent-air intake terminals.
Always install furnace to operate within the furnace’s
intended temperature-rise range with a duct system
which has an external static pressure within the
allowable range, as specified in the “Complete
Installation” section of these instructions. See
furnace rating plate.
■
The furnace shall be installed so the electrical
components are protected from water.
■
Furnaces for indoor installation on combustible
flooring shall not be installed directly on carpeting,
tile or other combustible material other than wood
flooring.
SAVE THESE INSTRUCTIONS
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including benzene, formaldehyde, carbon
monoxide, toluene, and soot.
ADDITIONAL SAFETY INFORMATION
In the State of Massachusetts, the following installation instructions apply:
■
■
■
2
Installations and repairs must be performed by a qualified or licensed contractor, plumber, or gasfitter qualified or licensed by
the State of Massachusetts.
If using a ball valve, it shall be a T-handle type.
A flexible gas connector, when used, must not exceed 3 feet.
INSTALLATION REQUIREMENTS
These instructions are intended as a general guide only for use by
qualified persons and do not supersede any national or local
codes in any way. Compliance with all local, state, or national
codes pertaining to this type of equipment should be determined
prior to installation.
Read this entire instruction manual, as well as the instructions
supplied in separate equipment, before starting the installation.
The installation of the furnace, wiring, warm air ducts, venting,
etc., must conform to the requirements of the National Fire
Protection Association; the National Fuel Gas Code, ANSI
Z223.1/NFPA No. 54 (latest edition) and the National Electrical
Code, ANSI/NFPA No. 70 (latest edition) in the United States, and
any state laws, local ordinances (including plumbing or
wastewater codes), or local gas utility requirements. Local
authorities having jurisdiction should be consulted before
installation is made. Such applicable regulations or requirements
take precedence over the general instructions in this manual.
This furnace design is certified by CSA International as a
Category IV furnace in compliance with the latest edition of
American National Standard Z21.47/CSA Standard 2.3 for GasFired Central Furnaces, for operation with Natural gas or
propane. Consult the rating plate on the furnace for gas type
before installing.
Location Requirements
WARNING
Explosion Hazard
Keep flammable materials and vapors, such as
gasoline, away from furnace.
Place furnace so that burners are at least 18 inches
(46 cm) above the floor for a garage installation.
Failure to follow these instructions can result in death,
explosion, or fire.
WARNING
Tools and Parts
Gather the required tools before starting installation. Read and
follow the instructions provided with any tools listed here.
Tools needed
■
Pipe wrench
■
Noncorrosive leak check solution
■
Screwdriver
■
■
Tape measure
Test gauge with ¹⁄₈" NPT connection
(for measuring gas supply pressure)
■
Thread sealant
■
Explosion Hazard
Do not install this furnace in a mobile home.
Level
Doing so can result in death, explosion, fire, or
carbon monoxide poisoning.
Parts needed
Check local codes and with gas supplier. Check existing gas
supply, electrical supply, and venting, and read “Ductwork
Requirements,” “Electrical Requirements,” “Gas Supply
Requirements,” “Venting Requirements” and “Installation
Configurations” before purchasing parts.
Parts supplied
■
Inlet air restrictor plate
■
Flue pipe screen
■
Condensate disposal kit
IMPORTANT: Do not use the furnace as a heater in a building
under construction. The furnace can be severely damaged due to
the abnormal environment caused by construction. Chlorides
from sources such as paint, stain, or varnish; tile and counter
cements; adhesives; and foam insulation are abundant in a
structure under construction and can be highly corrosive. Low
return air temperature can cause condensation in the furnace and
other damage that can shorten the life of the furnace.
■ The condensate system must not be exposed to
temperatures below 32°F. Insulating condensate system in
areas exposed to temperatures below 32ºF is necessary.
■
The furnace is suitable for installation in buildings
constructed on site. The furnace should be centralized in
respect to the heat distribution system as much as
practicable.
■
To avoid property damage caused by condensate drain
blockage, install a field-fabricated auxiliary drain pan with a
separate drain line to the outside under the entire furnace and
drain system. Install according to local codes.
3
All models are suitable for closet or utility room installation.
Utility room installation requires:
■
A door opening large enough for the widest part of the
furnace.
A door opening large enough to remove/replace any other
appliance located in the utility room, such as a water heater.
Any other appliances arranged so that each appliance can be
removed/replaced without disturbing the furnace.
In a residential garage, a gas-fired furnace must be installed
so the burner(s) and the ignition source are located not less
than 18" above the floor. The furnace is to be located or
protected to avoid physical damage by vehicles.
■
Ductwork Requirements
Install the conditioned air plenum, ducts and air filters (if not
provided on the furnace) in accordance with NFPA 90B Standard
for the Installation of Warm Air Heating and Air-Conditioning
Systems (latest edition).
The furnace is provided with flanges for the connection of the
plenum and ducts.
All air filters must be listed as Class 2 furnace air filters.
Electrical Requirements
WARNING
If the furnace is to be installed in an attic or other insulated
space, it must be kept free and clear of insulating materials.
■
Installation Clearances
■
A 2" minimum clearance is required in front for air openings
into the combustion chamber.
■
All servicing and cleaning of the furnace can be performed
from the front. If installed in a closet or utility room, provide
24" clearance in front for service if the door to the room is not
in line with the front of the furnace. Where servicing
clearances are greater than clearances to combustibles,
servicing clearances take precedence.
Electrical Shock Hazard
Electrically ground furnace.
Connect ground wire to green ground screw.
Failure to do so can result in death or electrical shock.
Minimum Clearance to Combustibles Chart
Upflow
Horizontal
Unit Sides
0"
0"
Rear of Unit
0"
0"
Front of Unit
2"
18"
Flue Pipe
0"
0"
Plenum Top (upflow)
1"
1"
Supply Duct (counterflow)
1"
1"
■
The furnace must be grounded and wired in accordance with
local codes or, in the absence of local codes, with the
National Electrical Code ANSI/NFPA No. 70 (latest edition).
■
In all instances, other than wiring for the thermostat, the
wiring to be done and any replacement of wire shall conform
with the temperature limitation for Type T wire (63°F rise).
■
The line voltage supply should be routed through a readily
accessible disconnect located within sight of the furnace. A
junction box on the furnace side panel is provided for line
voltage connections. See the furnace wiring diagram for
specific connection information.
■
Proper polarity of the supply connections (“HOT” and
“NEUTRAL”) must be observed to ensure that safety controls
provide the protection intended.
High Altitude Installations
■
This furnace is approved for operation at altitudes from 0 to
4,500 ft above sea level without any required modifications.
■
From 4,500 to 7,500 ft, the gas manifold pressure needs to be
adjusted according to the information shown in the Manifold
Pressure vs. Altitude Chart.
IMPORTANT:
For installations above 7,500 ft, the furnace input rate is to be
reduced according to the requirements of the National Fuel Gas
Code (ANSI Z223.1/NFPA 54, latest edition), at the rate of
4 percent for each 1,000 ft above sea level.
The furnace is not recommended for installation above 10,000 ft.
Installation Configurations
IMPORTANT: To ensure access to parts for servicing, install the
furnace so that the burner and blower access panels are readily
accessible.
4
Gas Supply Requirements
This furnace is equipped for use with Natural gas. A conversion
kit is required for use with propane. To order the correct
conversion kit, see “Accessories.”
■ Gas supply piping should be installed in accordance with
local codes and the regulations of the utility. Piping must be
of adequate size to prevent undue pressure drop. Consult the
local utility or gas supplier for complete details on special
requirements for sizing gas piping.
■
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously serviced another gas
appliance.
Venting Requirements
Adequate provisions for combustion air and ventilation of furnace
must be made. Refer to Section 5.3, “Air for Combustion and
Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA54
(latest edition), or applicable provisions of the local building
codes.
Unconfined Space
An unconfined space is defined as “a space whose volume is
more than 50 cu. ft per 1,000 BTU per hour of the combined input
rating of all appliances installed in that space.”
When a furnace is installed in an unconfined space in a building,
it can be assumed that the infiltration will be sufficient to supply
the required air.
If the furnace is installed in a ventilated attic or crawl space, it is
assumed that the air infiltration is sufficient to supply the required
combustion air. However, in a building of unusually tight
construction, additional outdoor air should be provided.
■
Furnaces installed in hobby or craft rooms
■
Furnaces installed near chemical storage areas
■
Furnaces installed in laundry rooms
■
Furnaces installed in hair salons
Indoor air as the source of combustion air
Indoor air as the source of combustion air is acceptable in most
applications if the following guidelines are met:
■ All provisions for indoor combustion air must meet the
requirements for combustion air indicated in the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 (latest edition), and/or any
applicable local codes.
■
Confined Space
If indoor combustion air is used, the air supply to the furnace
should not be exposed to the following substances:
Permanent wave solutions
A confined space is defined as “a space whose volume is less
than 50 cu. ft per 1,000 BTU per hour of the combined input
rating of all appliances installed in that space.” Use Direct Vent
method. See “Plan Vent System.”
Chlorinated waxes and cleaners
Chlorine-based swimming pool chemicals
Water softening chemicals
Contaminated Combustion Air
Deicing salts or chemicals
Carbon tetrachloride
Excessive exposure to contaminated combustion air will result in
performance related problems. The recommended source of
combustion air is outdoor air.
Outdoor air as the source of combustion air
If the furnace is installed in a confined space, it is recommended
that the necessary combustion air come from the outdoors by
way of an attic, crawl space, air duct, or direct opening.
Outdoor air is required as the source of combustion air when the
indoor air is contaminated with chemical substances and in the
following types of installations:
■ Furnaces installed in commercial buildings
■
Halogen-type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
Chlorinated laundry products
Hydrochloric acid
Furnaces installed in buildings with indoor pools
INSTALLATION INSTRUCTIONS
WARNING
Inspect Shipment
WARNING
Excessive Weight Hazard
Use two or more people to move and install furnace.
Explosion Hazard
Furnace must be installed and serviced by a
qualified person.
Examples of a qualified person include:
licensed heating personnel,
authorized gas company personnel.
Read and follow all instructions provided for
installation, adjustment, service, alteration, or
maintenance.
Failure to follow these instructions can result in death,
explosion, fire, or carbon monoxide poisoning.
Failure to do so can result in back or other injury.
This furnace is shipped in one package, completely assembled
and wired. The thermostat is shipped in a separate carton when
ordered.
■ Check the unit rating plate to confirm specifications are as
ordered.
■
Upon receipt of equipment, be sure to inspect it for possible
shipping damage. Be sure to examine the unit inside the
carton if the carton is damaged.
■
If damage is found, it should be noted on the carrier’s freight
bill. Damage claims should be filed with the carrier
immediately. Claims of shortages should be filed with the
seller within 5 days.
NOTE: If any damages are discovered and reported to the
carrier, do not install the unit, because your claim might be
denied.
5
■
Plan Vent System
The high efficiency of this furnace is accomplished by the
removal of both sensible and latent heat from the flue gases. The
removal of latent heat results in the condensation of moisture in
the flue gases. This condensation occurs in the secondary heat
exchanger and in the vent system. Therefore, this furnace
requires special venting considerations, and the instructions
must be followed to ensure proper operation. All venting must be
in accordance with the codes having jurisdiction in the area and
these instructions.
IMPORTANT:
■ The venting system must be supported with mounting straps
to prevent any weight load from being applied to the vent
blower. Horizontal vent pipe must be supported every 5 ft and
vertical pipe should be supported every 10 ft to prevent
sagging and provide rigid support.
■
■
In horizontal applications, the restrictor plate must be
secured to the inlet collar by inserting a field supplied piece of
2" or 3" PVC pipe into the inlet collar after the restrictor plate
is installed. Use high temperature RTV sealant to attach the
PVC to the inlet collar.
Flue Pipe Screen
A flue pipe screen designed to keep objects out of the flue pipe is
included in the plastic bag.
In all installations, this screen should be installed at the
termination of the flue pipe.
Flue Pipe Screen
This furnace must not be connected to any Type B, BW, or
L vent or vent connector and must not be connected to any
portion of a factory-built or masonry chimney.
The flue pipe screen
should be installed at the
termination of the flue pipe
in all installations.
This furnace is not to be common vented with any other
appliance. The vent pipe must not be connected to a
chimney flue serving a separate appliance designed to burn
solid fuel.
Venting Options
The furnace can be installed as either direct vent or nondirect
vent units.
For either type of installation, special venting considerations
must be followed. See “Determine Vent Pipe Direction” section
for the type of furnace and venting being installed.
Direct Vent
A direct vent (two pipe) installation requires that all the air
necessary for combustion be supplied from outside the dwelling
through an air intake pipe.
■ All vents passing through floors, ceilings, and walls must be
installed in accordance with National Fuel Gas Code, ANSI
Z223.1/NFPA 54 (latest edition). In all applications where the
flue pipe is run through an unconditioned space, ¹⁄₂"
insulation must be used over the pipe. In extremely cold
climates, ³⁄₄" insulation is recommended.
Nondirect Vent
A nondirect vent (one pipe) installation uses air from inside the
dwelling for combustion.
■ The furnace is shipped with the air inlet pipe terminated to the
top panel for either inside or outside combustion air. An inlet
air restrictor plate is supplied with this furnace and can be
found in the plastic bag containing these Installation
Instructions and the User’s Information Manual.
■
For installations using inside air for combustion (nondirect
vent), attach a 90° elbow (not supplied) to the inlet coupler
and install the restrictor plate inside the elbow (see
“Nondirect Vent Installation”).
Inlet Air Restrictor Plate
The inlet air restrictor plate
must be installed in all
nondirect vent systems.
6
A 2" restrictor plate is supplied with the 40, 60, 80 and
100k Btuh models. A 3" restrictor plate is supplied with the
125k Btuh model.
Materials
■
All pipe, fittings, primer, and solvent cement must conform
with American National Standard Institute and the American
Society for Testing and Materials (ANSI/ASTM) standards.
The solvent shall be free flowing and contain no lumps,
undissolved particles, or any foreign matter that adversely
affects the joint strength or chemical resistance of the
cement. The cement shall show no gelatinization,
stratification, or separation that cannot be removed by
stirring. See “Piping and Fitting Specifications” for approved
piping and fitting materials.
Piping and Fitting Specifications
Piping and Fitting Material
ASTM Specification
Schedule 40 PVC (Pipe)
D1785
Schedule 40 PVC (Cellular Core Pipe)
F891
Schedule 40 PVC (Fittings)
D2466
SDR-26 (Pipe)
D2241
Schedule 40 ABS (Pipe)
D1527
Schedule 40 ABS (Fittings)
D2468
Schedule 40 & 80 CPVC (Pipe)
F441
ABS-DWV Drain Waste & Vent
(Pipe & Fittings)
D2661
PVC-DWV Drain Waste & Vent
(Pipe & Fittings)
D2665
■
■
■
■
The primers and solvents used must also meet ASTM
specifications. PVC primer is specified in ASTM F656. Use
PVC solvent as specified in ASTM D2564 and ABS solvent
cement as specified ASTM D2235. Low temperature solvent
cement is recommended. Metal or plastic strapping may be
used for vent pipe hangers.
Vent Table—90,000 - 100,000 BTU/HR Models
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
5
NR 2
2
2
2
2
2
When making ABS joints, pieces can be prepared with a
cleaner. When joining ABS to PVC materials, use PVC solvent
cement as specified in ASTM D3138.
10
2
2
2
2
2
2
2.5 2.5 2.5 2.5
20
2
2
2
2
2
2.5 2.5 2.5 2.5 3
Preferred fittings are DWV style or long sweep. Seal all joints
gas tight with appropriate cement. In areas where vent and air
intake pipes are exposed to abnormal stress or are subject to
damage, schedule 80 pipe should be used.
30
2
2
2
2.5 2.5 2.5 2.5 3
40
2
2
2.5 2.5 2.5 3
Use high temperature RTV silicone sealant to attach the air
intake pipe into the connector on the burner box so the air
intake pipe can be removed if service is required.
50
2.5 2.5 2.5 3
3
60
2.5 3
3
3
NOTE: Do not use cement.
70
3
3
3
3
80
3
3
3
NR NR NR NR NR NR NR
90
3
3
NR NR NR NR NR NR NR NR
Number of 90°
Elbows
0
1
2
Vent Pipe Size and Length
The vent pipe and air intake pipe (in direct vent installations)
should be sized in accordance with the information found in the
Vent Table charts. One 90° elbow is equivalent to 5 ft of pipe. Two
45° elbows are equivalent to one 90° elbow. The minimum length
certified for use with this furnace is 5 ft and one elbow, not
including the vent and air intake terminals.
3
2.5 2.5 2.5
3
3
3
3
3
3
3
3
3
3
NR
3
3
3
NR NR NR
3
NR NR NR NR NR
4
5
6
7
8
9
NR = Not Recommended
Vent Table—112,000 - 125,000 BTU/HR Models
Vent Table—40,000 - 80,000 BTU/HR Models
Number of 90º Elbows
Vent Pipe
Length (ft)
Minimum Pipe Diameter (in.)
Vent Pipe
Length (ft)
0
2
3
4
5
6
7
8
9
5
2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
5
1.5 1.5 2
2
2
2
2
2
2
2
10
2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 3
10
1.5 2
2
2
2
2
2
2
2
2
20
2.5 2.5 2.5 2.5 2.5 2.5 2.5 3
20
2
2
2
2
2
2
2
2
2
2.5
30
2.5 2.5 2.5 2.5 2.5 3
40
2.5 2.5 2.5 2.5 3
30
2
2
2
2
2
2
2
2.5 2.5 2.5
50
2.5 3
3
40
2
2
2
2
2
2.5 2.5 2.5 2.5 2.5
60
3
3
NR NR NR NR NR NR NR NR
50
2
2
2.5 2.5 2.5 2.5 2.5 2.5 2.5 3
0
1
2
60
2
2.5 2.5 2.5 2.5 2.5 2.5 3
70
2.5 2.5 2.5 2.5 2.5 3
3
80
2.5 2.5 2.5 3
3
3
90
2.5 2.5 3
3
3
1
NR = Not Recommended
3
3
3
Number of 90°
Elbows
3
3
NR
NR = Not Recommended
3
3
NR NR
3
NR NR NR
3
3
NR
NR NR NR
NR NR NR NR NR
NR NR NR NR NR NR NR
3
4
5
6
7
8
9
In the event that the pipe length is in between the lengths listed in
the Vent Table, use the next larger length listed. For example, if a
length of pipe needed to install the furnace is 27 ft, use the
diameter values for the 30 ft row in the tables.
For direct vent installations, if the vent and air intake pipe are not
equal in length and number of elbows, then determine the
minimum pipe diameter for both the vent and air intake. If the
results indicate different diameters, use the larger of the two for
both the vent and air intake.
NOTE: Under no circumstances should the vent and air intake
pipe size be different in diameter. See “Plan Vent System” for the
unit model and type of installation.
7
Determine Vent Pipe Direction
The vent system of the furnace must be self-supporting and must not apply any weight load to the combustion blower.
Combustion Air Sources
There are 2 sources for combustion air:
1. From outside the building (Direct Vent)
2. From inside the building (Nondirect Vent)
Please read the information provided here about Vertical and
Horizontal Venting, then find and follow the instructions for your
venting configuration.
Vertical Venting
A vertical vent should extend through the roof a minimum of 2 ft
and not be obstructed a minimum of 10 ft in any direction.
Horizontal Venting
The vent terminal location shall comply with the National Fuel
Gas Code (ANSI Z223.1) or local requirements. For informational
purposes, the side wall terminal vent clearances are shown in the
“Sidewall Vent Terminal Clearances” tables.
Sidewall Vent Terminal Clearances—Direct Vented Furnaces (Horizontal Venting)
V Vent Terminal
X Air Supply Inlet
Area Where Terminal Is
Not Permitted
A Clearance above grade, veranda, porch, deck, or balcony
B Clearance to window or door that may be opened
C Clearance to permanently closed window
D Vertical clearance to ventilated soffit located above the
terminal within a horizontal distance of 2 ft from the center
line of the terminal
E Clearance to unventilated soffit
F Clearance to outside corner
G Clearance to inside corner
H Clearance to each side of center line extended above
meter/regulator assembly
I Clearance to service regulator vent outlet
J Clearance to nonmechanical air supply inlet to building or
the combustion air inlet to any other appliance
U.S. Installations1
12"
6" for appliances less than 10,000 Btuh, 9" for appliances greater
than 10,000 Btuh, and less than or equal to 50,000 Btuh, 12" for
appliances greater than 50,000 Btuh
*
*
*
*
*
*
*
6" for appliances less than or equal to 10,000 Btuh, 9" for
appliances greater than 10,000 Btuh, and less than or equal to
50,000 Btuh, 12" for appliances greater than 50,000 Btuh
3 ft above if within 10 ft horizontally
*
K Clearance to a mechanical air supply inlet
L Clearance above paved sidewalk or paved driveway
located on public property
M Clearance under veranda, porch, deck, or balcony
*
1
In accordance with the current ANSI Z2223.1/NFPA 54, National Fuel Gas Code.
*Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation
instructions.
8
Sidewall Vent Terminal Clearances—Nondirect Vented Furnaces (Horizontal Venting)
V Vent Terminal
X Air Supply Inlet
Area Where Terminal Is
Not Permitted
A
B
C
D
U.S. Installations1
12"
4 ft below or to side of opening; 12" above opening
*
*
Clearance above grade, veranda, porch, deck, or balcony
Clearance to window or door that may be opened
Clearance to permanently closed window
Vertical clearance to ventilated soffit located above the terminal within a
horizontal distance of 2 ft from the center line of the terminal
E Clearance to unventilated soffit
*
F Clearance to outside corner
*
G Clearance to inside corner
*
H Clearance to each side of center line extended above meter/regulator
*
assembly
I Clearance to service regulator vent outlet
*
J Clearance to nonmechanical air supply inlet to building or the combustion 4 ft below or to side of opening; 12" above opening
air inlet to any other appliance
K Clearance to a mechanical air supply inlet
3 ft above if within 10 ft horizontally
L Clearance above paved sidewalk or paved driveway located on public
7 ft
property
M Clearance under veranda, porch, deck, or balcony
*
1
In accordance with the current ANSI Z2223.1/NFPA 54, National Fuel Gas Code.
*Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer’s installation
instructions.
9
Direct Vent Installation—Upflow Installations
■
Refer to the appropriate vent table for proper pipe size, vent
length and the number of elbows allowed, and air intake
length and the number of elbows allowed.
■
Refer to the “Materials” section for the proper venting
material.
■
Do not install the inlet air restrictor plate in any direct vent
installation. The inlet air restrictor plate (see “Inlet Air
Restrictor Plate” section) supplied with this furnace is to be
used only in nondirect vent applications.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
■
For proper operation, the vent and air intake pipe must be
installed in the same pressure zone. Therefore, in horizontal
venting applications they must be on the same side of the
house within the parameters as shown.
NOTE: The 18" dimension shown below is the minimum
recommended height for extremely cold areas. In these
areas, moisture in the flue gases may condense and freeze on
the air intake if this height is reduced. In milder climates, this
may be reduced to a minimum of 6". Height may be
increased as needed provided total length of pipe to furnace
is not exceeded.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
Direct Vent—Upflow (Horizontal Venting)
Direct Vent—Upflow (Vertical Venting)
6.5" Min. - 24" Max.
Run Pitch =
¹⁄₄" Per Ft
Minimum
C
D
E
18"
C
D
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
E
F
6"
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
THRU.
A
B
DRAIN
(CLOSED)
HOLE
59.69/56.64
G
A
Run Pitch =
¹⁄₄" Per Ft
Minimum
F
Overhead View
G
E
C
B
F
3" Min. - 48" Max.
A. Air intake pipe
B. Condensate collar
C. Optional piece
10
D. Flue pipe screen (inside flue pipe)
E. Flue pipe
F. Air intake pipe
G. Wall
A. Flue pipe
B. Condensate collar
C. Flue pipe screen (inside flue pipe)
D. Storm collars
E. Flashing
F. Air intake pipe
Nondirect Vent Installation—Upflow Installations
■
Refer to appropriate tables for proper pipe size, vent length
and the number of elbows allowed.
■
Refer to the “Materials” section for the proper venting
material.
Nondirect Vent—Upflow (Horizontal Venting)
■
An inlet air restrictor plate found in the plastic bag containing
these Installation Instructions and the User’s Information
Manual must be installed in all nondirect vent installations.
See the “Inlet Air Restrictor Plate” section. Install the inlet air
restrictor plate inside the inlet coupler. Attach a 90° elbow
(not supplied) to the inlet coupler.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
Nondirect Vent—Upflow (Vertical Venting)
Run Pitch =
¹⁄₄" Per Ft
Minimum
A
A
D
Height to Provide 6" Minimum to Roof.
Adjust Height to Expected Snow
Level Based on Local Conditions.
C
6"
Height to Provide 12"
Clearance to Expected
Snow Level Based on
Local Conditions.
B
B
E
(CLOSED)
DRAIN
HOLE
59.69/56.64
THRU.
C
Run Pitch =
¹⁄₄" Per Ft
Minimum
A. Flue pipe
B. Inlet air restrictor plate
(inside inlet coupler)
C. Condensate collar
D. Flue pipe screen
(inside flue pipe)
E. Air intake pipe
D
E
F
G
A. Flue pipe screen (inside flue pipe)
B. Storm collar
C. Flashing
D. Flue pipe
E. Air intake pipe
F. Inlet air restrictor plate
(inside inlet coupler)
G. Condensate collar
11
Direct Vent Installation—Horizontal Installations
■
Refer to the appropriate vent table for proper pipe size, vent
length and the number of elbows allowed, and air intake
length and the number of elbows allowed.
■
Refer to the “Materials” section for the proper venting
material.
■
Do not install the inlet air restrictor plate in any direct vent
installation. The inlet air restrictor plate (see “Inlet Air
Restrictor Plate” section) supplied with this furnace is to be
used only in nondirect vent applications.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
■
For proper operation, the vent and air intake pipe must be
installed in the same pressure zone. Therefore, in horizontal
venting applications they must be on the same side of the
house within the parameters as shown.
NOTE: The 18" dimension shown below is the minimum
recommended height for extremely cold areas. In these
areas, moisture in the flue gases may condense and freeze on
the air intake if this height is reduced. In milder climates, this
may be reduced to a minimum of 6". Height may be
increased as needed provided total length of pipe to furnace
is not exceeded.
NOTE: Do not place an additional flue pipe screen in the
intake termination because the air intake may freeze shut.
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Right to Left)
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Left to Right)
A
B
18"
6"
A B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C
A. 3" long piece of 2" diameter pipe
B. Drain tee (in kit)
C. Height to provide 12" minimum clearance. Adjust height
to expected snow level based on local conditions.
Direct Vent—Horizontal (Horizontal Venting—Horizontal
Left to Right Alternate Venting for Low Clearance
Installations)
A
B
C
18"
6"
D
A. 3" long piece of 2" diameter pipe
B. 2 each of 2" 90º street elbows
C. Drain tee (in kit)
D. Height to provide 12" minimum clearance. Adjust height
to expected snow level based on local conditions.
12
Direct Vent—Horizontal (Vertical Venting—Horizontal Right
to Left)
Direct Vent—Horizontal (Vertical Venting—Horizontal Left
to Right)
6.5" Min. - 24" Max.
6.5" Min. - 24" Max.
C
C
B
A
A
B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Height to provide 6" minimum to roof. Adjust height to
expected snow level based on local conditions.
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Height to provide 6" minimum to roof. Adjust height to
expected snow level based on local conditions.
Nondirect Vent Installation—Horizontal Installations
■
Refer to appropriate tables for proper pipe size, vent length
and the number of elbows allowed.
■
Refer to the “Materials” section for the proper venting
material.
Nondirect Vent—Horizontal (Horizontal Venting—
Horizontal Right to Left)
■
An inlet air restrictor plate found in the plastic bag containing
these Installation Instructions and the User’s Information
Manual must be installed in all nondirect vent installations.
See the “Inlet Air Restrictor Plate” section. Install the inlet air
restrictor plate inside the inlet coupler. Attach a 90° elbow
(not supplied) to the inlet coupler.
■
The flue pipe screen, designed to keep objects out of the flue
pipe (see “Flue Pipe Screen” section), should be installed at
the termination of the flue pipe.
Nondirect Vent—Horizontal (Horizontal Venting—
Horizontal Left to Right)
A
B
6"
C
C
A
B
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Inlet air restrictor plate (inside inlet coupler)
A. 3" long piece of 2" diameter pipe
B. Drain tee (in kit)
C. Inlet air restrictor plate (inside inlet coupler)
13
Nondirect Vent—Horizontal (Vertical Venting—Horizontal
Right to Left)
Existing Venting Systems
When an existing furnace is removed or replaced, the original
venting system may no longer be sized to properly vent the
attached appliances. An improperly sized venting system can
result in spillage of flue products into the living space, the
formation of condensate, leakage, etc. See the “Carbon
Monoxide Poisoning Hazard” for proper test procedure.
A
WARNING:
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide
poisoning or death.
B
C
D
A. Height to provide 6" minimum to roof. Adjust height
to expected snow level based on local conditions.
B. 3" long piece of 2" diameter pipe
C. Drain tee (in kit)
D. Inlet air restrictor plate (inside inlet coupler)
Nondirect Vent—Horizontal (Vertical Venting—Horizontal
Left to Right)
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and
Propane Installation Codes and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an
unsafe condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other
spaces of the building.
C
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they are operating
at maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so
appliance is operating continuously.
A
B
D
A. Drain tee (in kit)
B. 3" long piece of 2" diameter pipe
C. Height to provide 6" minimum to roof. Adjust height
to expected snow level based on local conditions.
D. Inlet air restrictor plate (inside inlet coupler)
14
7. Test for spillage from draft hood equipped appliances at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance
with the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CSA B149.1, Natural Gas and Propane Installation
Codes.
9. After it has been determined that each appliance connected
to the venting system properly vents when tested as
outlined above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-fired burning
appliances to their previous conditions of use.
Connect Venting
1. Run venting to the furnace, see “Plan Vent System.”
2. Attach the air intake pipe to the furnace connector.
Use high temperature RTV silicone sealant to attach the air
intake pipe into the connector on the burner box so the air
intake pipe can be removed if service is required.
NOTE: Do not use cement.
3. For nondirect vent installations only, install the inlet air
restrictor plate in the air inlet pipe. See Nondirect vents in
“Venting Options” for details.
4. Install tee assembly for condensate drain as shown
(horizontal applications only).
5. Attach the flue pipe connector to the furnace.
Horizontal Right to Left
6. For both direct and nondirect vent installations, install the flue
pipe screen at the outside end of the flue pipe.
7. Make sure all vent connections do not leak.
8. Check that the exhaust vent pipe terminates outside the
building.
9. Prime the trap system by slowly pouring 1 cup of water down
the vent pipe. The vent pipe on horizontal runs must slope
upward, away from the furnace, at a minimum pitch of ¹⁄₄" per
foot of run, to prevent accumulation of condensate.
NOTE: On initial start-up of the unit, some of the water used
to prime the trap system may run down into the combustion
blower and cause noise.
Horizontal Left to Right
A
B
C
D
D
A
B
C
A. 2" x 2" x ¹⁄₂" ppt supplied in kit
B. To vent pipe
C. 3" nipple supplied in kit
D. Flue pipe
A. 2" x 2" x ¹⁄₂" ppt supplied in kit
B. To vent pipe
C. 3" nipple supplied in kit
D. Flue pipe
Install Condensate Disposal
Upflow Installation
2. Connect the plastic pipe plug opposite of the drain.
3. Connect ³⁄₄" PVC pipe, make a connection from the adapter
just installed to extend just outside the unit. Install a ³⁄₄" PVC
tee as shown.
4. From the PVC tee, connect the drain to the disposal area.
NOTE: The top of the PVC tee must be left open for proper
condensate drainage. The open end of the PVC tee must be
oriented so that the condensate does not run out of this
opening.
THRU.
Condensate Disposal
B
C
59.69/56.64
IMPORTANT: The condensate drain should be routed directly to
a locally acceptable disposal area. The condensate drain line
should not be run directly to the outdoors especially in colder
climates where temperatures may cause the condensate to
freeze in the drain line.
1. Connect the ¹⁄₂" NPT x ³⁄₄" PVC adapter (supplied) in the drain
on the side that the draining will occur.
NOTE: The condensate can be drained from either the right
or left side of the furnace.
A
A. ¹⁄₂" NPT plug (supplied)
B. ³⁄₄" PVC pipe
D
C. PVC tee (must remain open)
D. ¹⁄₂" NPT x ³⁄₄" PVC adapter (supplied)
15
Horizontal Installation—Left to Right Airflow
3. Insert external trap assembly (supplied in kit) into flue pan.
A
B
IMPORTANT:
■ The condensate drain should be routed directly to a locally
acceptable disposal area. The condensate drain line should
not be run directly to the outdoors especially in colder
climates where temperatures may cause the condensate to
freeze in the drain line.
Furnace must be mounted such that the side through which
the condensate will drain is elevated a minimum of 9" above a
surface such as a floor.
■
Install unit at a slight pitch forward with shims or adjusting
screws.
■
A. Flue pan
B. Condensate drain and external trap assembly
(supplied in kit) with ³⁄₄" PVC pipe outlet
4. Connect a length of ³⁄₄" PVC pipe (3 ft minimum) to the
external trap assembly (supplied in kit).
5. Install a ³⁄₄" PVC tee as shown.
¹/₄" Max
1. Relocate ¹⁄₂" NPT plug from the flue pan to the internal trap
assembly.
2. Connect the ¹⁄₂" NPT plug (supplied in kit) to the opposite side
of the internal trap assembly from the NPT plug installed in
Step 1.
C
A
B
A. ³⁄₄" PVC tee
B. 72" piece of ³⁄₈" vinyl hose
C. ³⁄₄" PVC pipe
6. From the ³⁄₄" PVC tee, connect the drain to the disposal area.
NOTE: The top of the PVC tee must be left open for proper
condensate drainage. The open end of the PVC tee must be
oriented so that the condensate does not run out of this
opening.
A
B
C
A. ¹⁄₂" NPT plug (supplied in kit)
B. Internal trap assembly
C. ¹⁄₂" NPT plug
16
7. Connect one end of vinyl hose (supplied in kit) to the ³⁄₈"
barbed fittings of the 2" x 2" x ¹⁄₂" PVC tee in vent and the
other end to the ³⁄₈" barbed fitting on the drain trap assembly.
IMPORTANT: Be sure to avoid double-trapping the vinyl hose.
Hose must be installed as shown above.
Horizontal Installation—Right to Left Airflow
2. Connect the ¹⁄₂" NPT plug (supplied in kit) to the opposite side
of the internal trap assembly from the NPT plug installed in
Step 1.
A
B
IMPORTANT:
■ The condensate drain should be routed directly to a locally
acceptable disposal area. The condensate drain line should
not be run directly to the outdoors especially in colder
climates where temperatures may cause the condensate to
freeze in the drain line.
■
Furnace must be mounted such that the side through which
the condensate will drain is elevated a minimum of 9" above a
surface such as a floor.
■
Install unit at a slight pitch forward with shims or adjusting
screws.
¹/₄" Max
C
A. ¹⁄₂" NPT plug (supplied in kit)
B. Internal trap assembly
C. ¹⁄₂" NPT plug (supplied in kit)
3. Insert external trap assembly (supplied in kit) into the flue
pan.
A
1. Relocate ¹⁄₂" NPT plug from the flue pan to the internal trap
assembly.
B
A. Flue pan
B. Condensate drain and external trap assembly
(supplied in kit) with ³⁄₄" PVC pipe outlet
17
4. Connect a length of ³⁄₄" PVC pipe (3 ft minimum) to the
external trap assembly (supplied in kit).
5. Install a ³⁄₄" PVC tee as shown.
6. From the ³⁄₄" PVC tee, connect the drain to the disposal area.
NOTE: The top of the PVC tee must be left open for proper
condensate drainage. The open end of the PVC tee must be
oriented so that the condensate does not run out of this
opening.
7. Remove vinyl hose from kit and cut in half. Connect one end
of the hose to the ³⁄₈" barbed fitting on the vent PVC tee.
Connect the other end of the vinyl hose to the ³⁄₈" barbed
fitting on the drain trap assembly.
IMPORTANT: Be sure to avoid double-trapping the vinyl hose.
Hose must be installed as shown above.
A
B
C
A. ³⁄₄" PVC tee
B. 36" piece of ³⁄₈" vinyl tubing
C. ³⁄₄" PVC pipe
Connection to Pressure Switch
Upflow Installation
Horizontal Right to Left Installation
NOTE: Black hose is factory-connected to the 0.10" W.C.
pressure switch. Other end of hose must be field-connected to
flue pan. Remove plastic cap plug from ¹⁄₄" port on flue pan
(discard cap plug) and connect hose to port.
NOTE: Black hose is factory-connected to the 0.10" W.C.
pressure switch. Other end of hose must be connected to
external drain trap. Route hose through gas line access hole in
cabinet. Then connect to ¹⁄₄" barbed fitting on drain trap
assembly.
A
B
A
B
A. 0.10" W.C. pressure switch
B. Black hose
IMPORTANT: Be sure that the pressure switch hoses do not
form a trap to hold condensation that could result from the flue
gas. Hose may be cut shorter to avoid forming a trap, if required.
A. 0.10" W.C. pressure switch
B. Black hose
IMPORTANT: Be sure that the pressure switch hoses do not
form a trap to hold condensation that could result from the flue
gas. Hose may be cut shorter to avoid forming a trap, if required.
18
Horizontal Left to Right Installation
NOTE: Black hose is factory-connected to the 0.10" W.C.
pressure switch. Other end of hose must be connected to
external drain trap. Route hose through gas line access hole in
cabinet. Then connect to ¹⁄₄" barbed fitting on drain trap
assembly.
A
B
A. 0.10" W.C. pressure switch
B. Black hose
IMPORTANT: Be sure that the pressure switch hoses do not
form a trap to hold condensation that could result from the flue
gas. Hose may be cut shorter to avoid forming a trap, if required.
Filter Specifications
Upflow Models
A filter rack and cleanable 16" x 25" x ¹⁄₂" filter are supplied with
this furnace. (Models designed for more than 1,600 CFM nominal
air delivery include two of each.)
Some model furnaces can be installed with either a side or
bottom air return. For bottom air return the bottom air return
knockout plate must be removed. For furnaces that do not
include a side or bottom return filter rack, Kit Number AFILT524-1
(side return) or Kit Number AFILT529-1 (bottom return) can be
used.
To provide sufficient filter area for installations requiring more
than 1,600 CFM nominal air delivery, return air will have to be
brought through both sides of the furnace, or through one side
and the bottom, or through a separate return air grille not located
on the product.
Minimum Filter Requirements Chart
Disposable Filters
Cleanable Filters
Min.
Area
Airflow
Descriptor (sq. in.)
Size
(in.)
IMPORTANT:
■ Install ductwork in accordance with NFPA 90B and any local
codes.
09
480
20 x 25
1
240
16 x 20
1
10
480
20 x 25
1
240
16 x 20
1
If there is no complete return air duct system, the return air
connection must be sealed to the furnace casing and run full
size to a location outside the utility room or space housing
the furnace to prevent a negative pressure on the venting
system.
12
576
16 x 20
2
288
16 x 20
1
14
672
20 x 20
2
336
20 x 20
1
16
768
20 x 20
2
384
20 x 20
1
20
960
20 x 25
2
480
20 x 25
1
Install Ductwork
■
Installation with Return Ducts
A return air duct system is recommended. If the furnace is
installed in a confined space or closet, a return connection must
be run, full size, to a location outside the closet. The air duct in
the closet must be tight to prevent any entrance of air from the
closet into the circulating air.
Min.
Area
Qty. (sq. in.)
Size
(in.)
Qty.
If a central return air filter-grille is used, the furnace does not
require a filter.
To install a filter at the furnace only, use the following kits:
■ AFILT524 for side return on upflow installations.
■
AFILT529 for bottom return on upflow furnace installations.
Installation with an Evaporator Coil
When an air conditioning furnace is used in conjunction with the
furnace, the evaporator coil must be installed in the discharge
(supply) air. Do not install an evaporator coil in the return air;
excessive condensation will occur within the furnace.
Installation without an Evaporator Coil
If a cooling coil is not installed with the furnace, then a removable
access panel should be provided in the supply plenum for
purposes of inspecting the heat exchanger. This opening must be
accessible when the furnace is installed. It must be large enough
that the heat exchanger can be viewed for possible openings
using light assistance or so that a probe can be inserted for
sampling the airstream. The cover for the opening must be
leakproof.
19
Make Electrical Connections
WARNING
Electrical Shock Hazard
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Electrically ground furnace.
Replace all parts and panels before operating.
Connect ground wire to green ground screw.
Failure to do so can result in death or electrical shock.
Failure to do so can result in death or electrical shock.
Thermostat
Install a room thermostat according to the instructions furnished
with it. Select a location on an inside wall that is not subject to
drafts, direct sunshine, or other heat sources.
Make the low voltage thermostat connections to the ignition
control board as indicated on the Wiring Connection Diagram in
“Troubleshooting.”
1. Disconnect power.
2. Remove the screw from the furnace electrical connection
box.
3. Remove the cover from the furnace electrical connection box.
4. Route the field supply wires to the furnace electrical
connection box.
5. Using UL listed wire nuts, connect the field supply wires to
the furnace (black to black and white to white).
6. Connect ground wire to green ground screw.
A
B
A. Connect white to white and black to black
B. Green ground screw
7. Replace the furnace electrical connection box cover and
screw.
Make Gas Connections
IMPORTANT: This furnace requires conversion for use with
propane. To order the correct conversion kit, see “Accessories.”
1. Install the field gas supply as shown.
2. Provide a sediment trap on the outside of the furnace.
3. Install a manual gas shutoff valve in the gas line, outside the
furnace, 5 ft above the floor, or in accordance with any local
codes.
4. Install a test gauge connection with a ¹⁄₈" NPT plugged tap
immediately upstream of the manual gas shutoff valve as
shown.
20
5. Connect the gas pipe to the furnace controls providing a
ground joint union as close to the controls as possible to
facilitate removal of controls and manifold.
Pipe-joint compounds suitable for use with Natural and LP
gas must be used. Do not use Teflon® tape.
13. Turn on the gas supply at the manual gas shutoff valve.
14. Test all connections by brushing on an approved
noncorrosive leak-detection solution. Bubbles will show a
leak. Correct any leak found.
■ At test pressures greater than ¹⁄₂ psig (3.5 kPa), the
furnace and the manual gas shutoff valve must be
disconnected from the gas supply piping system.
A
At test pressures less than or equal to ¹⁄₂ psig (3.5 kPa),
the furnace must be isolated from the gas supply piping
system by closing the manual gas shutoff valve.
■
B
C
15. Replace the burner access door.
Check the Furnace Input Rate
(if required)
D
IMPORTANT:
■ The furnace input rate must not exceed the input rating on
the furnace rating plate.
E
F
G
A. ¹⁄₈" NPT plugged tap
B. Manual gas shutoff valve
C. Ground joint union
D. Tee
E. Sediment trap
F. Cap
G. Gas control valve
(inside furnace)
■
This furnace is equipped for rated input at manifold pressures
of 3.5" W.C. for Natural gas and 10.0" W.C. for propane gas.
■
For Natural gas, check the furnace rate by observing the gas
meter, making sure all other gas appliances are turned off.
The test hand on the meter should be timed for at least one
revolution.
BTU/HR =
Cu. ft per Revolution
x 3600 x Heating
INPUT
Value
# Seconds per Revolution
WARNING
■
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
6. Turn off the gas supply at the manual gas shutoff valve.
A
B
A. Closed valve
B. Open valve
7. Remove the inlet pressure tap plug on the gas control valve
and connect pressure gauge to the ¹⁄₈" NPT inlet
pressure tap.
8. Turn on the gas supply at the manual gas shutoff valve.
9. Observe the inlet pressure.
The minimum inlet gas supply pressure is 5" W.C. for Natural
gas and 11" W.C. for propane gas.
The maximum inlet gas supply pressure is 10.5" W.C. for
Natural gas and 13" W.C. for propane gas.
10. Turn off the gas supply at the manual gas shutoff valve.
IMPORTANT: If the inlet gas supply pressure is not within the
minimum and maximum range as shown on the rating plate,
contact your gas supplier.
11. Disconnect the pressure gauge from the ¹⁄₈" NPT inlet
pressure tap.
12. Replace the inlet pressure tap plug on the gas control valve.
At altitudes from 2,000 to 7,500 ft the furnace input rate must
not exceed that on the rating plate.
NOTE: The actual heating value of your gas can be obtained from
your local utility company. Typical values are shown in the
Manifold Pressure vs. Altitude Chart.
Adjust the Furnace Input Rate
(if required)
For altitudes 4,500 to 7,500 ft above sea level
1. Remove the burner access door.
2. Move the gas control knob to the Off position. Use only your
hand to move the gas control knob; tools are not required.
3. Remove the outlet pressure tap plug on the gas control valve
and connect pressure gauge to the ¹⁄₈" NPT outlet
pressure tap.
Gas Control Valve
A
ON
Failure to follow the safety warnings exactly could result
in serious injury, death or property damage.
OFF
FIRE OR EXPLOSION HAZARD
D
B
E
C
F
A. Gas control knob
B. ¹⁄₂" NPT outlet
C. ¹⁄₈" NPT outlet pressure tap
D. ¹⁄₈" NPT inlet pressure tap
E. ¹⁄₂" NPT inlet
F. Regulator adjusting burner
box reference tap
®Teflon is a registered trademark of E.I. Dupont de Nemours and
Company.
21
4. Be sure the gas control knob has been in the Off position for
at least 5 minutes before starting the furnace.
5. Move the gas control knob to the On position.
NOTE: This furnace is equipped with an ignition device which
automatically lights the burner. This furnace cannot be lighted
manually. Do not try to light the burner by hand.
6. Turn on the electrical power to the furnace.
7. Set the room thermostat to a point above room temperature
to light the main burners.
8. Observe the pressure reading on the pressure gauge.
9. Refer to the Manifold Pressure vs. Altitude Chart for the
correct manifold pressure. If necessary, remove the regulator
adjusting burner box reference tap on the gas valve (has
barbed fitting and hose on sealed combustion units) and turn
the regulator adjusting screw clockwise to increase pressure
and input, or counterclockwise to decrease pressure and
input.
IMPORTANT: If the manifold pressure cannot be adjusted to
the correct value, contact your gas supplier.
10. Move the gas control knob to the Off position.
11. Disconnect the pressure gauge from the ¹⁄₈" NPT outlet
pressure tap.
12. Replace outlet pressure tap plug and the regulator adjusting
burner box reference tap (has barbed fitting and hose on
sealed combustion units) on the gas valve.
13. Move the gas control knob to the On position.
14. Replace the burner access door.
15. Set the room thermostat to the desired temperature
necessary to achieve optimum temperature rise.
Complete Installation
IMPORTANT: Do not use this furnace if any part has been under
water. Immediately call a qualified person to inspect the furnace
and to replace any part of the control system and gas control
which has been under water.
1. Be sure you have all of your tools.
2. Dispose of/recycle all packaging materials.
3. Check the furnace in its final location. Be sure the vent is not
blocked.
Measure Temperature Rise
1. After 20 minutes of heating operation, measure the furnace
temperature rise. Take air temperature readings in both the
return air ducts and the heated air ducts (about 6 ft from the
furnace where they will not be affected by radiant heat) as
shown.
NOTE: If more than one run of return or heated air ducts is
used, air temperature measurements should be taken in each
duct. These measurements can be converted to an average
to obtain the temperature rise of the whole system.
Warm Air
B
A
Manifold Pressure vs. Altitude Chart for Natural Gas
Altitude (ft)
Manifold
Heating Value Pressure
(BTU/ft3)
(in. W.C.)
Input
Factor
2,000
948
3.5
0.9666
3,000
914
3.5
0.9499
4,000
881
3.5
0.9332
4,500
865
3.5
0.9249
5,000
849
3.29
0.89
5,500
833
3.27
0.879
6,000
818
3.25
0.868
6,500
802
3.23
0.857
7,000
787
3.21
0.846
7,500
771
3.19
0.835
For altitudes 7,500 to 10,000 ft above sea level
Do not adjust manifold pressure. An orifice change is required.
For the correct orifice size, see Table F.4 in Appendix F of the
National Fuel Gas Code (ANSI Z223.1/NFPA 54, latest edition).
22
Return Air
A. Measure return air here.
B. Measure supply temperature here.
2. If furnace doesn't maintain temperature rise within the range
shown on the furnace rating plate, adjust the blower speed.
Adjust Blower Speed
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
NOTE: See the Wiring Connection Diagram in “Troubleshooting”
while performing the following procedure.
1. Disconnect power.
2. For heating speed, check the temperature rise and make the
necessary adjustments to the blower speed tap. See Wiring
Connection Diagram in “Troubleshooting.”
3. Reconnect power.
4. Recheck the temperature rise. Repeat the procedure as
necessary to achieve optimum temperature rise.
5. If the furnace does not begin to heat the room, see the
“Troubleshooting” section.
Fan On
During a fan on call, the thermostat energizes the R - G circuit of
the control board, immediately causing the fan to energize the
COOL speed. The fan remains energized as long as the
thermostat calls for fan on operation.
If a call for cooling is energized during a fan on call, the fan
continues to operate at the COOL speed. If a call for heat is
energized during a fan on call, the control de-energizes the fan
immediately and begins the heat call/ignition sequence.
At the end of the fan on call, the thermostat de-energizes the
R - G circuit of the control, causing the fan to be de-energized
immediately.
Cooling
During a call for cooling, the thermostat energizes the R - Y
circuit of the control board. After a 1-second cooling “on” delay,
the control energizes the cooling fan speed. If the fan is already
energized, it remains running and does not de-energize for the
1-second cooling fan “on” delay.
The call for cooling has priority over continuous fan operation
while a call for heating has priority over both a call for cooling or
continuous fan. Ignition lockouts for any reason do not affect
cooling operation.
As cooling demand is met, the thermostat de-energizes the R - Y
circuit of the control board. After a 60-second cooling “off” delay,
the control de-energizes the cooling speed fan. At the end of the
cooling “off” delay period, the control returns to the standby
mode.
Controls
Shut Down the Furnace
1.
2.
3.
4.
Set the room thermostat to the lowest setting.
Disconnect power.
Remove burner access door.
Shut off the gas by moving the gas control knob to the Off
position.
5. Replace the burner access door.
Sequence of Operation
Heating
During a call for heat, the thermostat closes R - W circuit of the
control board. The control board verifies limit switches are closed
and pressure switch is open. The induced draft blower relay
closes, causing the blower to run. As vent pressure is developed
by the induced draft blower, the pressure switch closes. After a
15-second pre-purge, the control energizes the hot surface
igniter. After a 7-second warm-up time, the control energizes the
main gas valve, causing the main burners to ignite. The hot
surface igniter is de-energized 3 seconds after the main valve
opens. If flame is sensed during this time, the main valve remains
energized and the control starts the 30-second heat blower “on”
delay.
As heating demand is met, the thermostat de-energizes the R - W
circuit. The control de-energizes the main valve, causing the
burners to shut off. The induced draft blower shuts off after a
15-second post-purge delay. The circulating air blower will
continue to operate until the user-selectable heat blower “off”
delay expires. The control returns to standby mode once the heat
blower “off” delay expires.
Pressure Switch(es)
The pressure switch is a normally open switch that monitors
combustion airflow. Inadequate airflow resulting from excessive
venting system restriction or a failed combustion blower will
cause the switch to remain open.
Rollout Switch(es)
The rollout switch(es) are normally closed switch(es) that open
when abnormal temperatures exist in the burner area. This can
be caused by a restricted heat exchanger, causing main burner
flame to “roll out” into the vestibule area or burner box.
The rollout switch(es) must be manually reset by pushing the
button on top to restore furnace operation.
Primary Limit Control
This is a normally closed control that opens if abnormally high
circulating air temperatures occur. It is an automatic reset control.
Auxiliary Limit Control (on some models)
This is a normally closed control, located on the circulating air
blower housing, that opens under abnormal “reverse airflow”
conditions that could occur in a counterflow or horizontal
installation if the circulating air blower fails. It is an automatic
reset control.
Safety Interlock Switch
When the blower door is removed, the safety interlock switch
breaks the power supply to the burner controls and blower motor.
23
Ignition Control Board
WARNING
The ignition control board operates the gas valve, circulating air
blower, combustion blower and any accessories connected to it.
The ignition control contains control logic to sense proper
operating conditions and provides ignition only when all
conditions are properly met.
These models feature user-selectable blower “off” delay times
(60, 90, 120 and 180 seconds) that are factory-set to provide a
120-second blower “off” delay on heating. See Wiring
Connection Diagram in “Troubleshooting.”
Gas Control Valve
The gas control valve regulates the manifold gas pressure and
provides gas flow.
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
TROUBLESHOOTING
Failure Codes
Control System Diagnostics
NOTE: The following visual checks should be made before
troubleshooting:
■ Check to see that the power to the furnace and the blower
control board is on.
LED Status
Fault Description
LED Off
No power to control or control hardware fault
detected
LED On
Normal operation
■
The manual shutoff valves in the gas line to the furnace must
be open.
1 Flash
Flame present with gas valve off
■
Check to be sure all wiring connections are secure.
2 Flashes
Pressure switch closed with inducer off
■
Review the “Sequence of Operation” section.
3 Flashes
Pressure switch open with inducer on
4 Flashes
High limit switch open
5 Flashes
Rollout switch open
6 Flashes
Pressure switch cycle lockout
7 Flashes
Lockout due to no ignition
8 Flashes
Lockout due to too many flame dropouts
9 Flashes
Incorrect line voltage phasing
1. Start the system by setting the thermostat above the room
temperature.
2. Observe the system’s response.
3. Use the information provided in this section to check the
system’s operation.
The furnace has a built-in, self-diagnostic capability. If a system
problem occurs, a failure code is indicated by the LED on the
ignition control board.
IMPORTANT: Do not remove the blower compartment door or
turn off the power to the furnace since either action will clear the
control’s memory of the fault.
The control continuously monitors its own operation and the
operation of the system. If a failure occurs, the LED will indicate
the failure code. See the Failure Codes chart.
24
Fault Code History Button
The control stores the last 5 fault codes in memory. A pushbutton switch is located on the control. When the push-button
switch is pressed and released, the control flashes the stored
fault codes. The most recent fault code is flashed first; the oldest
fault code is flashed last.
To clear the fault code history, press and hold the push-button
switch in for more than 5 seconds before releasing.
Wiring Connection Diagram—Honeywell® VR 8205 System
HOT SURFACE
IGNITER
LINE VOLTAGE - FACTORY
LINE VOLTAGE - FIELD
LOW VOLTAGE - FACTORY
LOW VOLTAGE - FIELD
G
W
BK
INTERLOCK
SWITCH
CIRCULATION
BLOWER
W (NEUT)
R (LO)
OR (MED/LO)
BU (MED)
Y (MED/HI)
BK (HIGH)
INDUCED
DRAFT
BLOWER
NOT ON ALL MODELS
W
BK/W STRIPE
Y
Y/BK STRIPE
R
BU
TRANSFORMER
MV
MV
BK
W
IF USED
OR
OR
HUM
L1
XFMR
CONT
EAC
COOL
HEAT
NEUTRALS
Y
W
Y
BK
ROLLOUT
SWITCH
OR
ROLLOUT
SWITCH
PARK
PARK
PARK
W
FAULT CODE
HISTORY
BUTTON
(SEE NOTE 1)
HIGH
LIMIT
BR
R CW Y G
60
90
120
180
TWIN
FLAME
SENSOR
GY
5A FUSE
60
90
120
180
GAS
VALVE
V
SW1
BLOWER OFF
DELAY TIMING
(SEE NOTE 3)
AUX
LIMIT
V
V
AUX
LIMIT
PRESSURE
SWITCH
(if used)
PRESSURE
SWITCH
IF USED
THERMOSTAT & SUBBASE
HEAT ANTICIPATOR
0.60 AMP
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
CONDENSER
Check codes for proper wiring and circuit protection before
installation.
NOTES:
1. Press and release fault code history button to display fault
codes. To erase codes, press and hold button in for more
than 5 seconds.
2. If any of the original wire as supplied with the furnace must be
replaced, it must be replaced with wiring material having a
temperature rating of at least 194ºF (90ºC).
3. Blower off delay timing is factory set at 120 seconds. To
change, move the jumper to the pins adjacent to the desired
setting.
Failure to do so can result in death or electrical shock.
25
Wiring Schematic—Honeywell® VR 8205 System
26
ASSISTANCE OR SERVICE
If you need further assistance, you can write to the below
address with any questions or concerns:
Whirlpool® Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258
Please include a daytime phone number in your correspondence.
Accessories
To order accessories ask for the appropriate part number listed
below or contact your Whirlpool® Home Cooling and Heating
dealer.
ALPKT572-3
Natural Gas to Propane Conversion Kit
AFILT524-1
Side Return Filter Kit
AFILT529-1
Bottom Return Filter Kit
27
47861K005
© 2005. All rights reserved.
Honeywell is a trademark of Honeywell International, Inc.
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida
11/05
Printed in U.S.A.
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